Glass block panel construction and device for use in same

ABSTRACT

Architectural glass block walls or panels are constructed by assembling a plurality of blocks using connectors which provide securement and uniform spacing of the blocks in a width and height direction. Each connector comprises a pair of rigid, elongated members each having a pair of spaced, planar opposite surfaces, and a laterally centered longitudinal groove in each surface. Each member is joined to the other member and each connector is disposed at an intersection of the corners of and in abutment with a plurality of blocks with each longitudinal groove engaging a ridge which extends around the circumference of each block. The connectors can be secured to the blocks with an adhesive compound, e.g., a curable silicone caulking composition, and the space between the blocks can be filled with mortar, grout or caulking material to seal the wall or panel and embed and conceal the connectors in the mortar.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation-in-part of application Ser. No. 843,483, filedMar. 24, 1985, abandoned.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates to walls or panels of glass blocks and to devicesand methods used in constructing such walls or panels. Moreparticularly, the invention relates to architectural glass block wallsor panels containing connectors which facilitate construction andprovide enhanced structural integrity and strength to the wall or panel.The terms "wall" and "panel" are used interchangeably herein and eachconnotes the other as well as partitions, windows and other structuresfor which architectural glass blocks have heretofore been used.

2. Description of Related Art

Glass blocks are architecturally favored as a construction material fromthe standpoint of their usefulness in forming panels having anaesthetically pleasing appearance, thermal and sound insulating ability,weather resistance coupled with low maintenance requirements, resistanceto vandalism and forced entry, and ability to transmit light tovirtually any desired degree to provide optimum illumination.

Most commonly used glass blocks, and the ones to which this inventionapplies, are formed by fusing together two halves of pressed glass whichresults in an upstanding central projection or ridge around the middleof the circumference of the block. Ordinarily, glass blocks areassembled in a panel on-site using mortar, cement, grout, or caulkingmaterial as is the practice with regular bricks or cement blocks. Suchpanels can be also be pre-assembled elsewhere and shipped to the jobsite.

Unfortunately, the non-porous, non-absorbent surfaces of glass blocks donot permit the formation of a strong bond with mortar, and severalschemes have been devised to overcome this drawback. For example, thecircumferential surfaces of some glass blocks are roughened by themanufacturer; also, resinous coatings have been applied to such surfacesto which the mortar used in setting the blocks can better adhere.

In laying up glass blocks, greater care is needed than with bricks orother types of masonry. Glass blocks are usually laid up in straight,horizontal courses and vertical tiers rather than overlapping as in thecase of bricks, and it is important architecturally, aesthetically andstructually, that the blocks be uniformly spaced, both horizontally andvertically. Also, because glass blocks are relatively heavy and sincethey do not absorb water from the mortar as do bricks or concreteblocks, the mortar should be used in a firmer mix to support the weightof the blocks. Moreover, since mortars that are suitable for use inlaying glass blocks are of the type which set slowly, only a few coursesof blocks can be laid up at a time; otherwise, the weight of freshlylaid blocks will tend to squeeze out the mortar between the lowercourses, thus making it difficult to align the glass blocks properly.Special fast-setting mortars are sometimes used in order to try to avoidthis problem, but this is less desirable from a structural standpoint.

For all of these reasons, glass block panels, despite theirarchitectural advantages, are often avoided by builders and others whomust pay the relatively high labor cost in constructing them.

A number of efforts have been made over the years to facilitate theconstruction of glass block panels. These efforts generally have beenaimed at providing spacing and reinforcement in the form of pins,spacers, anchors, and the like as shown in U.S. Pat. Nos. 1,798,088;1,868,236; 2,112,241; 2,227,842; 2,239,537; 2,527,985; 3,295,281; and4,058,943. However, none of these methods has gained acceptance in thearchitectural profession or building trades, either because such methodsare not applicable to glass blocks of conventional design, or becausetheir use requires the exercise of skill beyond that possessed by thetypical mason, or because they just don't work well enough or are noteconomical enough to justify their commercial use.

A need therefore exists for an innovative means to facilitate the layingof glass blocks, and for glass block panels and a method forconstructing such panels which are more economical and of better qualitythan were previously attainable.

Accordingly, it is an object of present invention to provide a means forfacilitating the laying of glass blocks to form panels.

Another object is to provide glass block panels of novel and improvedconstruction compared to glass block panels made previously.

Yet another object is to provide a novel method for constructing glassblock panels which is faster, easier and more economical than methodsheretofore used and which results in the advantageous glass block panelsof the present invention.

These and other objects of the invention as well as a fullerunderstanding of the advantages thereof, can be had by reference to thefollowing description and claims.

SUMMARY OF THE INVENTION

The foregoing objects are achieved according to the present inventionone aspect of which is a connector for glass blocks for use in formingan architectural wall or panel of said blocks. The connectors areinserted between the blocks as they are laid up and provide securementin a width and height direction. The connectors impart a structuralrigidity, resilience and reinforcement to the panel complementary to themortar so that the courses and tiers of blocks can be more readilysecured in accurate alignment and with uniform spacing.

In one of its forms wherein the connector can be used in constructingflat walls or panels, the connector comprises a pair of rigid,interlocked, elongated, rectilinear members. Each member has two spaced,parallel, planar opposite surfaces, a longitudinal groove in eachsurface, and an open slot perpendicular to the longitudinal directionand extending to the lateral center of the member. (As used herein, term"surface" includes a surface as such, as well as elements which definesuch surfaces as illustrated, for example, in FIGS. 5 and 6). Eachmember can thus be disposed or fitted within the slot of the othermember. Preferably, the grooves in each member are laterally centered,i.e., each groove is centered relative to the width of the member. Whenthe connector is to be used to join four blocks at a commonintersection, e.g., within the boundaries of the wall or panel, the slotin each member is preferably longitudinally centered, i.e., is locatedmidway along the length of the member. When the connector is to be usedto join two blocks at a common intersection, e.g., along the edge of thepanel where it meets a sill or jamb, the slot in one of the membersshould be located at or near the end of the member and the slot in theother member is preferably directed midway along the length of themember (i.e., longitudinally centered) so that the connector has a "T"configuration.

Another form of the connector, which is particularly useful inconstructing glass block walls or panels which are curved, comprises apair of rigid, interlocked, elongated members one of which has twospaced, parallel planar opposite surfaces; the other member is taperedin the sense that it has two spaced, nonparallel, laterally converging,planar opposite surfaces. Each member has a longitudinal groove,preferably laterally centered, in each surface and an open slot, asdescribed in the preceding paragraph. Each member can thus be disposedor fitted within the slot of the other member.

The connector can be made of any rigid material (e.g., wood, plastic,metal, glass, ceramic). Among these materials, plastics, e.g.,polystyrene, rubber-modified polystyrene (also known as "impactpolystyrene" or "high impact polystyrene"), polycarbonate, acrylic,nylon, and the like, are preferred because of their desirable mechanicalproperties (e.g., stiffness and compressive strength), resistance todecomposition, availability in a variety of colors and degrees oftransparency, and relatively low material and fabrication costs. Thesimple geometry of the connectors facilitates fabrication by means thatwill become readily apparent to those skilled in the art having thebenefit of the present disclosure before them. In this regard, theconnectors can be fabricated in one piece rather than as separateinterlockable members, each member being thereby integrally molded withthe other member to form the connector as a single article ofmanufacture. In the case of connectors that are made of plastic, suchfabrication of the connector as a single piece can be convenientlycarried out by injecting molding. Also, connectors that abut a sill orjamb can, if desired, be made conveniently from a full connector bysimply cutting off half of one member; the other member, which abuts thesill or jamb, remains intact.

In another aspect of the invention, an architectural wall or panel whichcan be flat or curved or which can have separate flat and curvedportions, comprises a plurality of uniformly spaced glass blocks eachhaving a height, width and thickness and a ridge around the middle ofits circumference, and a plurality of connectors connecting the blocks.Each connector comprises a pair of rigid, interlocked, elongatedmembers, the length of each member being less than the shorter of theheight or width of a block and the width of each member being less thanthe thickness of the block. The thickness of the member, i.e., thedistance between its surfaces, determines the spacing between adjacentblocks. To facilitate mating of the connector with the block, thelongitudinal groove in said member is at least as wide and as deep as,and preferably wider and deeper than, the width and height,respectively, of the circumferential ridge on the block, the connectorbeing otherwise constituted as described hereinabove. The connectors aredisposed or located one each at an intersection of the corners of and inabutment with a plurality of blocks. Each longitudinal groove in theconnector members engages a ridge on a block to give lateral stabilityto the wall or panel; in the case of curved walls or panels containingconnectors having a member with non-parallel surfaces, the groove insuch member is perpendicular to the radius and arc of curvature of thewall or panel. Further, by using an adhesive such as a silicone caulkingcompound to secure the surfaces of each connector to the blocks withwhich they abut, an exceptional degree of flexural strength is impartedto the overall panel structure. This facilitates filling the spacesbetween the blocks with mortar to embed and conceal the connector withinthe mortar thereby to seal the wall or panel, e.g., against sound andweather.

In a third aspect of the invention, a method of forming the aforesaidwall or panel comprises connecting the blocks by interposing connectorsas described hereinabove, in the spaces between and in abutment withadjacent blocks in the manner described hereinabove. It is preferred tofirst lay up the entire panel with glass blocks and connectors usingsilicone caulking compound or the like as an adhesive between theconnectors and glass blocks, and thereafter apply a mortar such asPortland cement grouting to the spaces between the blocks, to completethe structure. If the mortar is applied to the glass blocks as thecourses are laid, a less safisfactory result is likely because themortar may interfere with proper mating and abutment of the connectorswith the blocks.

DESCRIPTION OF THE DRAWINGS

Referring to the drawings,

FIG. 1 is an elevational view in perspective of a representative portionof a flat wall or panel of glass block construction according to theinvention;

FIG. 2 is an elevational view in perspective of a representative portionof a glass block wall or panel of curved construction to the invention;

FIG. 3A is an elevational view in perspective of a connector accordingto the invention which is useful for constructing walls or panels of thetype shown in FIG. 1;

FIGS. 3B and 3C are elevational views in perspective of the two memberswhich are fitted or interlocked to form the connector shown in FIG. 3A;

FIG. 4 A is an elevational view in perspective of a connector accordingto the invention which is useful for constructing curved walls or panelsof the type shown in FIG. 2;

FIGS. 4B and 4C are elevational views in perspective of the two memberswhich are fitted or interlocked to form the connector shown in FIG. 4A.

FIG. 5 is an elevational view in perspective of a connector according tothe invention which is useful for constructing walls or panels of thetype shown in FIG. 1 and which is injection molded as a single piece ofplastic; and

FIG. 6 is an elevational view in perspective of a connector according tothe invention which is useful in constructing curved walls or panels ofthe type shown in FIG. 2 and which is injection molded as a single pieceof plastic.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, a representative portion 1 of a flat panel iscomprised of glass blocks 3, 5, 6 and 7 which are available in a varietyof sizes from Pittsburgh Corning Corporation of Pittsburgh, Pa. and fromWesterwald AG of Wirges, Germany. The size of each block is expressed interms of its thickness 9, height 11, and width 13. Standard sizes forglass blocks include thicknesses of 31/8" and 37/8", and widths andheights of 53/4"×53/4" (6" nominal), 73/4"×73/4" (8" nominal),113/4"×113/4" (12" nominal), 33/4"×73/4" (4"×8" nominal), and53/4"×73/4" (6"×8" nominal). Each block has a ridge 15 around the centerof the circumference and edges 17 and 19 which extend beyond the surface21 of the circumference. The surface 21 of the circumference usually hasa resinous coating or etched texture as determined by the manufacturerfor the purpose of improving the bond between the mortar and the blockand to control to some extent the transmission of light through the face23 of the block. As in conventional glass block panels, the spacing 25between the edges of adjacent blocks and between the edges of a blockand an adjacent sill or jamb is usually between about 1/4" and 5/8". Inthe panel of the present invention this is readily achieved byinterposing between the blocks the connectors 27, 29, 30 and 31 of thepresent invention as shown in FIG. 1. "T" shaped connectors 27 and 29are designed to abut against a jamb or sill; connectors 30 and 31illustrate the joining of four blocks at a common intersection. FIG. 1.also illustrates the feature of the invention wherein the panel isconstructed initially using only blocks and connectors, preferably withan adhesive self-curing silicone caulking compound applied to thesurface of the members of the connectors that will abut thecircumferential surfaces of the glass blocks to obtain a self-supportingstructure in which the connectors are load bearing. The entire wall isthus assembled and then the mortar e.g., Portland cement grouting, isapplied to fill in all the spaces between the blocks to seal the paneland to embed the connectors entirely within the mortar so that theconnectors cannot be seen. Suitable mortars or grounting include thoseheretofore used in laying up glass blocks. An exemplary grouting is madeby slurrying a mixture of 1 part by volume Portland cement, 1/4 to 1/2parts by volume lime, and sand equal to between about 21/4 and 3 timesthe volume of cement-plus-lime. If desired, a waterproofing agent can beapplied or waterproof Portland Cement can be used. Other suitablemortars, cements, grouts and caulking materials will suggest themselvesto those skilled in the masonry art having the benifit of the presentdisclosure before them. In this regard, the fact that the length of eachmember constituting the connectors is less than the width or height of aglass block with which it abuts makes it possible to establish themortar as an uninterrupted continuum or matrix throughout the panel. Thefinished panel is thus obtained in a fraction of the time and with abetter workmanship - like appearance than glass block panels madeheretofore.

Referring to FIGS. 3A, 3B and 3C, connector 33 suitable for use in theglass block panel of FIG. 1 is comprised of identically shaped rigid,elongated, rectilinear members 35 and 36. Each member is typically about3 inches long and about 2 inches wide and has two spaced, parallel,planar opposite surfaces 37 and 39, a longitudinal groove 41 about 1/8"deep in each surface, and an open slot 43 about 3/8" to about 1/2" wideand perpendicular to the longitudinal direction and extending to thelateral center of the member. Each member is about 3/8" or about 1/2"thick depending on the desired spacing of the blocks and correspondingto the width of the slot and can thus be disposed or fitted within theslot of the other member. As shown in FIGS. 3B and 3C, the grooves ineach member are tapered (e.g., from about 1/2" to about 3/8" for betterengagement with the ridge on the block) and laterally centered, i.e.,each groove is centered relative to the width of the member. Also, asshown in FIGS. 3B and 3C, when the connector is to be used to join fourblocks at a common intersection, e.g., within the boundaries of the wallor panel, the slot is preferably longitudinally centered, i.e., islocated midway along the length of the member. As shown by elements 25and 27 in FIG. 1 where the connector is to be used to join two blocks ata common intersection, e.g., along the edge of the panel where it meetsa sill or jamb, the slot in one of the members should be located at ornear the end of the member and the slot in the other member ispreferably located midway along the length of the member (i.e.,longitudinally centered).

FIG. 2 illustrates a representative portion 45 of a curved wall or panelof the invention. The curved wall can be constructed of the same glassblocks described above with regard to FIG. 1 except that the spacing 47between blocks of adjacent vertical tiers is greater on the convex sideof the panel then the corresponding spacing on the concave side. Minimumradii of curvature have been established in the building trade for thevarious sizes of glass blocks; such radii are generally such that thespacing between tiers on the concave side of the panel is no less thanabout 3/16" and no greater than about 3/8" on the convex side.

FIGS. 4A, 4B and 4C illustrate a connector 49 suitable for use in thecurved glass block panel shown in FIG. 3. The connector 49 comprises apair of rigid, interlocked, elongated members 51 and 53 one of which(53) has two spaced, parallel planar opposite surfaces 55 and 57; theother member 51 is tapered in the sense that it has two spaced,non-parallel, laterally converging, planar opposite surfaces 59 and 61.The angle of the taper matches the angle between adjacent vertical tiersof glass blocks which in turn determines the radius of curvature of thepanel. Each member 51 and 53 has a longitudinal groove 63, preferablylaterally centered, in each surface and an open slot 65 as described inthe preceding paragraph. Each member can thus be disposed or fittedwithin the slot of the other member.

FIGS. 5 and 6 illustrate connectors of the type which can be fabricatedin one piece from injection molded plastic, e.g., impact polystyrene.The element numbers in FIG. 5 bearing the suffix "a" correspond to theelement numbers in FIGS. 3A-3C; the element numbers in FIG. 6 bearingthe suffix "a" correspond to the element numbers in FIGS. 4A-4C.Although not shown as such, the connectors of FIGS. 5 and 6 preferablyhave chamfered or filleted angles and curves throughout. Connectors 33aand 49a differ from those illustrated FIGS. 3A and 4A respectively, inthat they are fabricated in one piece rather than as separateinterlockable members, and the surfaces are defined by element 37a, 39a,55a, 57a, 59a and 61a rather than by entirely flat areas (as in FIGS. 3Aand 4A) in order to facilitate injection molding by cutting down on thetotal thickness of the material. Thus, in the embodiments show in FIGS.5 and 6, the connectors having the dimension described hereinabove forFIGS. 3A-3C and 4A-4C would have a maximum material thickness of about1/8". Also, the connectors are depicted in FIGS. 5 and 6 in theorientation in which they are installed between glass blocks, i.e., thecross-elements are placed horizontally to take advantage of the factthat they impart load-bearing capacity to the connector. Although notshown, the vertical members are preferably tapered slightly (e.g., about1°) in order to facilitate removal of the connector from the injectionmold in which it is formed. Also, connectors of the type shown in FIGS.5 and 6 can be made in the form of interlockable members as shown inFIGS. 3A-3C and 4A-4C.

The foregoing description is intended to illustrate the invention, andit is understood that changes and variations can be made in theforegoing embodiments without departing from the spirit and scope of theinvention which is defined in the following claims.

I claim:
 1. A connector for glass blocks for use in forming a curvedpanel of said blocks, comprising a pair of rigid, interlocked, elongatedmembers one of which has but two spaced, parallel, planar oppositesurfaces and the other member having but two spaced, non-parallel,laterally converging planar opposite surfaces, each member having alongitudinal groove in each surface and an open slot perpendicular tothe longitudinal direction and extending to the lateral center of themember, each being interlockably disposed within the slot of the othermember, said connector being further characterized in that each memberis adapted to extend no further than the center of a side of a block onwhich said member abuts.
 2. A connector according to claim 1 wherein thegrooves are laterally centered.
 3. A connector according to claim 2wherein the slot in each member is longitudinally centered.
 4. Aconnector according to claim 2 wherein the slot in one member is locatednear the end of said member and the lot in the other member islongitudinally centered.
 5. A curved panel having a radius of curvature,comprising:a plurality of uniformly spaced glass blocks each having aheight, width and thickness and a ridge around its circumference, and aplurality of connectors for said blocks, each connector comprising apair of rigid, interlocked longitudinal members each member abutting theheight or width of each of at least two adjacent blocks, the length ofeach member being less than said height or width and the lateral widthof each member being less than the thickness of a block, one memberhaving but two spaced, parallel planar opposite surfaces and the othermember having, but two spaced, non-parallel, laterally converging planaropposite surfaces, each member having a longitudinal groove in eachsurface at least as wide and as deep as the width and the height,respectively, of the ridge on the block, and an open slot perpendicularto the longitudinal direction and extending to the lateral center of themember, each member being interlockably disposed within the slot of theother member, each connector being disposed at an intersection of thecorners of and in abutment with a plurality of blocks with eachlongitudinal groove engaging the ridge on a block and the longitudinalgroove in the member of each connector that has the non-parallelsurfaces being perpendicular to the radius of curvature of the panel,said connectors being further characterized in that each member of aconnector extends no further than the center of a side of a block onwhich said member abuts.
 6. A panel according to claim 5 wherein theconnectors are secured to the blocks with an adhesive.
 7. A panelaccording to claim 6 wherein the spaces between the blocks are filledwith mortar.
 8. A method of forming a curved panel having a radius ofcurvature and being comprised of uniformly spaced glass blocks eachhaving a height, width and thickness and a ridge around itscircumference, comprising connecting the blocks by interposing in thespace between and in abutment with adjacent blocks a connectorcomprising a pair of rigid, interlocked elongated members each memberabutting the height or width of at least two adjacent blocks, the lengthof said member being less than said height or width and the lateralwidth of each member being less than the thickness of the block, onemember having but two spaced, planar parallel opposite surfaces and theother member having but two spaced, non-parallel, laterally convergingplanar opposite surfaces, each member having a longitudinal groove ineach surface at least as wide and as deep as the width and height,respectively, of the ridge on the block, and an open slot perpendicularto the longitudinal direction and extending to the lateral center of themember, each member being interlockably disposed within the slot of theother member, each connector being disposed at an intersection of thecorners of and in abutment with two or more blocks with eachlongitudinal groove engaging the ridge on a block and the longitudinalgroove in the member of each connector that has non-parallal surfacesbeing perpendicular to the radius of curvature of the panel, saidconnector being further characterized in that each member of a connectorextends no further than the center of the side of a block on which saidmember abuts.
 9. A method according to claim 8 wherein the connectorsare secured to the blocks with an adhesive.
 10. A method according toclaim 9, wherein the spaces between the blocks are filled with mortar.11. A connector for glass blocks for use in forming a curved panel ofsaid blocks, comprising a pair of rigid, interlocked, elongated, unitarymembers one of which has but two spaced, parallel, planar oppositesurfaces and the other member having but two spaced, non-parallel,laterally converging planar opposite surfaces, each member having alongitudinal groove in each surface and each member being integrallymolded with the other member to form the connector as a single article,said connector being further characterized in that each member of aconnector extends no further than the center of the side of a block onwhich said member abuts.
 12. A connector according to claim 11 whereinthe grooves are laterally centered.
 13. A curved panel having a radiusof curvature, comprising:a plurality of uniformly spaced glass blockseach having a height, width and thickness and a ridge around itscircumference, and a plurality of connectors for said blocks, eachconnector comprising a pair of rigid, unitary elongated members eachmember abutting the height or width of each of at least two adjacentblocks, the length of each member being less than said height or widthand the lateral width of each member being less than the thickness of ablock, one member having but two spaced, parallel planar oppositesurfaces and the other member having but two spaced, non-parallel,laterally converging planar opposite surfaces, each member having alongitudinal groove in each surface at least as wide and as deep as thewidth and the height, respectively, of the ridge on the block, and eachmember being integrally molded with the other member to form theconnector as a single article, each connector being disposed at anintersection of the corners of and in abutment with a plurality ofblocks with each longitudinal groove engaging the ridge on a block andthe longitudinal groove in the member of each connector that has thenon-parallel surfaces being perpendicular to the radius and arc ofcurvature of the panel, said connector being further characterized inthat each member of a connector extends no further than the center ofthe side of a block on which said member abuts.
 14. A panel according toclaim 13 wherein the connectors are secured to the blocks with anadhesive.
 15. A panel according to claim 14 wherein the spaces betweenthe blocks are filled with mortar.
 16. A method of forming a curvedpanel having a radius of curvature and being comprised of uniformlyspaced glass blocks each having a height, width and thickness and aridge around its circumference, comprising connecting the locks byinterposing in the space between and in abutment with adjacent blocks aconnector comprising a pair of rigid, unitary elongated members eachmember abutting the height or width of at least two adjacent blocks, thelength of said member being less than said height or width and thelateral width of each member being less than the thickness of the block,one member having two spaced, planar parallel opposite surfaces and theother member having two spaced, non-parallel, laterally convergingplanar opposite surfaces, each member having a longitudinal groove ineach surface at least as wide and as deep as the width and height,respectively, of the ridge on the block, each member being integrallymolded with the other member, to form the connector as a single article,each connector being disposed at an intersection of the corners of andin abutment with two or more blocks with each longitudinal grooveengaging the ridge on a block and the longitudinal groove in the memberof each connector that has nonparallel surfaces being perpendicular tothe radius and arc of curvature of the panel.
 17. A method according toclaim 16, wherein the connectors are secured to the blocks with anadhesive.
 18. A method according to claim 17, wherein the spaces betweenthe blocks are filled with mortar.